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presentations: Dubai2011: Valid-processes-Mar2-wksp orig 1/28/11 rev 2/11/11 print 2/15/2011 12:06 PM 1
VALIDATING
THE RETAIL FOOD PROCESS
SIXTH DUBAI INTERNATIONAL FOOD SAFETY CONFERENCE
2 MARCH 2011
8:30 AM to 12:30 PM
O. Peter Snyder, Jr., Ph.D.
Hospitality Institute of Technology and Management
670 Transfer Road, Suite 21A; St. Paul, MN 55114
TEL 651 646 7077 FAX 651 646 5984 e-mail: [email protected] website: http://www.hi-tm.com
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THE FOOD HAZARDS:
Chemical
Physical
Biological
The farmer / supplier and the cook
are the principal hazard controllers.
ACTIVE MANAGERIAL CONTROL HACCP: There will be a Person In Charge of food safety on duty at all times, who will:
1. Identify hazards in the daily operation of the establishment.
2. Develop and implement policies, procedures, and standards to prevent foodborne illness.
3. Coordinate employee training so that they can demonstrate food safety knowledge; take
corrective action as needed to protect consumer health.
4. Conduct periodic self-inspections of daily operations to ensure that food safety policies and
procedures are followed.
The regulator approves the manager's HACCP plan and employee control.
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HOW DO YOU EVALUATE FOOD SAFETY IN A FOOD OPERATION / SYSTEM?
1. There is a Person In Charge (PIC) who is certified and:
Has identified the hazards.
Has developed and implemented policies, procedures, and standards
to control hazards to an Appropriate Level of Protection (ALOP) or
uses "safe harbor" controls from regulations.
Has coordinated training of employees so that they can demonstrate
hazard control.
Monitor daily employee performance of controls and coach them to
more certain performance.
2. The Regulatory Authority verifies the PIC's food safety management
plan (checklist) and the ability of the employee to demonstration hazard
control (training).
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AMC-HACCP FOOD SAFETY MANAGEMENT SYSTEM
RETAIL FOOD SYSTEM
Management Continuous HACCP Improvement
INPUT, Baseline Hazards
H0
Prerequisite Processes
FOOD HACCP PROCESS,
+ I - R Reduce hazard to a TLR* / ALOP*
OUTPUT, FSO*
Food with TLR* / ALOP*
Personnel with disease
Environment and facilities hazards
Pests, insects, birds, air
Contaminated water
Gas, solar, electric that can be
interrupted
Equipment / food contact surfaces cleaning and
maintenance
Supplies and material with
environmental and human
hazards, contamination,
various levels of nutrients and
spoilage, receive and store
Food processes I. Wash / trim, serve
II. Fermented, pH, aw preserved
food: cheese, yogurt, wine,
sauerkraut, cider, cold
smoked, dressing, salt, acid,
etc.
III. Pasteurized, serve
Meat, fish, poultry, vegetable,
starch
IV. Pasteurized and pH / aw
preserved: fruit / jams; BBQ;
meat, poultry; salted / smoked
fish, sausage; tomato,
hollandaise sauce; bread,
pastry
V. Sterilized
Leftovers
Serve -- carry-out
Transport / package
Consumer Food with a good balance
among pleasure, safety,
nutrition, convenience
Consumer food abuse
Consumer allergies,
intolerance, etc.
Waste Heat, contaminated air, smoke,
grease
Sewage, greywater
Glass, paper, metal, plastic
Food, grease
TLR = Tolerable Level of Risk ALOP = Appropriate Level Of Protection FSO = Food Safety Objective
Daily Operations
Report
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POTENTIAL HAZARDS IN THE FOOD SYSTEM
CHEMICAL PHYSICAL BIOLOGICAL
Poisonous Substances
Toxic plant material
Intentional (GRAS) food additives
Chemicals created by the process
Agricultural chemicals
Antibiotic and other drug residues in meat,
poultry, and dairy products
Unintentional additives
Sabotage
Equipment material leaching
Packaging material leaching
Industrial pollutants
Heavy metals
Radioactive isotopes
Adverse Food Reactions (food sensitivity)
Food allergens
Food intolerances
Metabolic disorder-based reactions
Pharmacological food reactions
Idiosyncratic reactions to food
Anaphylactoid reactions
Nutrition
Excessive addition of nutrients
Nutritional deficiencies and/or inaccurate
formulation of synthesized formulas
Anti-nutritional factors
Destruction and unnecessary loss of nutrients
during processing and storage
Hard Foreign Objects
Glass
Wood
Stones
Metal
Packaging materials
Bones
Building materials
Personal effects
Functional Hazards
Particle size deviation
Packaging defects
Sabotage
Choking / Food Asphyxiation
Hazards
Pieces of food, bone
Thermal Hazards
Food so hot that it burns tissue
Microorganisms and their Toxins
Bacteria: vegetative cells and spores
Molds [mycotoxins
(e.g., aflatoxin)]
Yeasts (Candida albicans)
Viruses and rickettsia
Parasites
Fish and Shellfish as Sources of
Toxic Compounds
Pests (birds, insects and rodents) as
carriers of pathogens: Filth from
insects, rodents, and any other
unwanted animal parts or excreta
Humans as carries of pathogens
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MICROORGANISMS LINKED TO ILLNESS CAUSES
Organism Cause
Campylobacter jejuni Food contact surface cross-contamination
Brucella spp.
Escherichia coli O157:H7
Salmonella spp.
Toxoplasma gondii
Trichina
Inadequate pasteurization / eating undercooked food
Food contact surface cross-contamination
Shigella
Norovirus
Hepatitis A and E
Rotavirus
Inadequate hand washing
Cryptosporidium
Cyclospora
Giardia lamblia
Drinking contaminated water or using contaminated water to
irrigate vegetables eaten fresh
Clostridium perfringens (spore) Inadequate hot holding / cooling too slowly
Bacillus cereus (spore)
Listeria monocytogenes Cold holding ready-to-eat food
Clostridium botulinum (spore) Pasteurized food allowed to incubate anaerobically at 20 to
30 C (~70 to 90 F), 1 to 2 days
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FOOD SAFETY MANAGEMENT SYSTEM
(OPERATIONS) MANUAL
BASED ON NACMCF / ICMSF / CODEX
9CFR 416 AND 9CFR 417)
MODEL MANUAL (963 KB) AVAILABLE AT: http://www.hi-tm.com/rfa/manu-tofc.html Preface
Log of changes
Reassessment Operations Description
System description
Organization
Environment (picture)
Facilities (plan)
Construction
Equipment (list)
Menu ingredient hazards (list) AMC-HACCP Management
Food safety policy
Responsibility and accountability
Emergencies
Food security / sabotage / recall
HACCP team / QC
Instrument / equipment calibration
Self-inspection, micro sampling
Corrective action
Training
Prerequisite Processes
Personal hygiene
Employee illness reporting
Hand washing: after toilet; after touching raw food
Glove use
First aid Environment
Pest control, water, storage Facilities
Cleaning, maintenance, cross-contamination
(Listeria) Equipment
Cleaning / sanitizing and maintenance of food
contact surfaces (CIP / COP) Supplies
Supplier HACCP certification
Ingredients supplier safe vs. cook safe
Receiving inspection
Storage: ambient, refrigerated, frozen
Control of physical, chemical, and biological
contamination
Food Process HACCP
Pre-preparation
Physical hazard control
Chemical hazard control
Allergen control
Thawing; bacterial control
Fruit and vegetable washing
Serving raw food Preparation
(cook-package or package-cook)
Salad and hors d'oeuvres
Pasteurization / sterilization
Ingredients to extend shelf life
Hot holding
Cooling
Cold holding
Leftovers / reprocessing Distributing / serving food
Communicating safe handling
Catering
Food Safety Management
Systems Manual
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FARM-TO-FORK FOOD SAFETY MANAGEMENT SYSTEM (FSMS) Science-Based Design of Hazard Control Processes
H0 + Increase - Reduction < FSO / ALOP
CMPS CMPS Land
Farm;
Water
Farm
Biological,
Chemical,
Physical
Food Hazards
Processor / distributor hazards
PO
Retail food
establishment Kitchen
Food market Deli
Control measures
and performance standards
Control measures
and performance standards
H0 (Hazard input) + I (Hazard increase) - R (Hazard reduction) FSO (Food Safety Objective)
FSO Food Safety Objective – A level/size of hazard that gives an ALOP to the consumer
(e.g., 1 Salmonella / 25 g)
ALOP / TLR Appropriate Level Of Protection / Tolerable Level of Risk
(e.g., Acceptable ill / 100,000; Acceptable dead / 1,000,000)
PO Performance Objective – Level of a hazard at end of step
(e.g., " 10 Salmonella in prepared chicken" before cooking)
CM Control measure – Any action taken to prevent, eliminate, reduce hazard
(e.g., "Wash fingertips by ___________.")
PS Performance Standard / Performance Criterion – hazard reduction in a step
(e.g., 5-log reduction of Salmonella)
International Commission of Microbiological Specifications for Foods (ICMSF). 2002. Microorganisms in Foods 7. Microbiological Testing and
Food Safety Management. Kluwer Academic Plenum Publishers. New York, NY.
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FOOD HAZARDS (H0) AND FOOD SAFETY OBJECTIVES (FSO)
Hazards Raw Product
Contamination (H0)
Process Performance Criteria (+ I-R)
Food Safety Objective (FSO)
MICROBIOLOGICAL (Reduce) INFECTIVE Vegetative pathogens - infection
Salmonella spp. / E. coli O157:H7 (food) 103 cfu/g 10
-5 cfu/g - reduce 10
-2 cfu/g or <1 cfu per 100 g
Shigella spp. (feces) (human) (fingertips) 106 cfu/g 10
-6 cfu/g - reduce 1-10 cfu/g or 1 cfu
Viruses Hepatitis A (human) (fingertips) >10 virus / g 10
-6 virus/g / reduce <1/g
Norovirus (human) (fingertips) >100 virus / g 10-6
virus/g / reduce <1/g Parasites
Cryptosporidium parvum (food) 1 cyst prevent / reduce undetectable Toxoplasma gondii (food) 1 cyst prevent / reduce undetectable Trichinella spiralis (food) 1-500 larvae prevent / reduce undetectable
TOXIN PRODUCING Staphylococcus aureus (exotoxin) (human) 10
3 cfu/g <10
3 cfu/g increase <10
6 cfu/g (toxin dose: <1 microgram)
SPORES Clostridium botulinum (exotoxin) (food) 1
spore / g <10
3 cfu/g increase <10
3 cfu/g (toxin dose: 2 nanograms)
Bacillus cereus (exotoxin, enterotoxin) (food) 102 spores / g <10
3 cfu/g increase <10
5 cfu/g (toxin dose: unknown)
Clostridium perfringens (enterotoxin) (food) 102 spores / g
<10
3 cfu/g increase <10
5 cfu/g (toxin dose: unknown)
CHEMICAL (Prevent / eliminate) Sulfites Variable none added <10 ppm Nitrates Variable <500 ppm added <500 ppm Nitrites Variable <200 ppm added <200 ppm Monosodium glutamate Variable 0.5 g / serving added <3.0 g / meal Allergens Aflatoxins (from mold) <20 ppb no increase <20 ppb Histamine (from fish, cheese) <20 ppm no increase <20 ppm PHYSICAL (Prevent / eliminate) Hard foreign objects (broken tooth) >1/16 inch (1.6 mm)
diameter prevent / remove <1/16 inch (1.6 mm) diameter
Choking >1/4 inch (6 mm) diameter
cut 1/4 inch (6 mm) <1/4 inch (6 mm)
Food burns (coffee) >170ºF (>76.7ºC) Warn
* cfu = colony forming units
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NACMCF / CODEX HACCP PROCESS ANALYSIS
HACCP, the scientific basis for a food process specification that will produce food products with an ALOP (Appropriate
Level of Protection). It started with NACMCF 1992 and 1998 Hazard Analysis and Critical Control Point and
Application Guidelines. It stated that a Food Safety Management System had four (4) parts:
1. System Description / Construction
2. Management of the System
3. Prerequisite Processes
4. Food HACCP Processes
HACCP is limited to food process hazards and controls, not prerequisite processes (mostly cleaning and maintenance). It states
that there are three (3) groups of hazards: biological, chemical, and physical. It prescribes that hazards can be controlled by
having a HACCP development team that begins by doing an accurate flow diagram of each process and then by applying the
HACCP process design principles / steps:
1. Conduct / identify the hazards at each step
2. Determine which are critical control points (CCP)
3. Specify critical limits and controls to prevent, eliminate or reduce the hazard to an ALOP.
4. Establish monitoring by the cook to control the process within the critical limits. What are the failure modes,
and what are the effects?
5. Establish corrective action.
6. Establish verification that the HACCP plan is functioning as intended.
7. Establish records and written documentation
It does not use the concept of Potentially Hazardous Food or Temperature and Time Control For Safety.
It makes decisions based on RISK.
Process Flow
Steps
H0 +I-R FSO / ALOP
Principles 1 & 2
Significant BCP
Hazard Analysis
(RISK
Principle 3
Critical Limit Control
& Validation for an
ALOP
Principle 4
Cook
Monitoring at
the Control
Principle 5
Corrective Action
Principles 6 & 7
Verification with
records &
documentation
Management
Prerequisite
Food
B
C
P
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APPLYING RISK ASSESSMENT TO THE HACCP PLAN The manager controls the risk
Risk is defined as Frequency of the hazard x Severity of the illness /injury. It is not statistically possible to
produce a zero risk food.
Significant BCP hazard analysis is done using the NACMCF 1998 Principles of Risk Assessment for Illness
Caused by Foodborne Biological Agents that provides the steps for doing the hazard / risk assessment and
risk control.
NACMCF HACCP PLAN
Process Flow
Steps
Principles 1 & 2
Significant BCP Hazard
Analysis (RISK)
Principle 3
Critical Limit Control &
Validation for an ALOP
Principle 4
Cook Monitoring
at the Control
Principle 5
Corrective
Action
Principles 6 & 7
Verification, Records
& Documentation
B
C
P
Risk Assessment Risk Control
BCP Hazard
Identification
Exposure Assessment,
Dose Response Risk Characterization
Risk
Management Risk Communication
Evidence of a
consumer
illness/injury base
on epidemiological
clinical research
evidence
Likely intake of the
hazard
Controls associated
with the process
Frequency and level of
contamination at
consumption
Dose Response
Quantity of hazard to
cause illness / injury
Percent of people
who will get ill
Severity of illness
and cost
ALOP
Number Ill
100,000 persons/yr
Risk evaluation
Risk management option
assessment
Implementation and management
of decisions
Monitoring and review
Risk is never zero
Communicate to the
consumer his/her
responsibility in risk
control
(Consumer Advisory)
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FOOD PROCESS PERFORMANCE-BASED DESIGN FOR SAFETY MICROBIOLOGICAL
Risk Factors (hazard source)
H0 (incoming hazard level)
+I (increase)
-R (reduction / control)
FSO (output)
Personal hygiene
Feces on fingers after using the toilet
and toilet paper
6 log Shigella/g, norovirus, hepatitis A No Double wash of fingertips with nail
brush for a 6-log reduction
1 CFU/g from fecal pathogens
on fingers
Infected cuts (sores) 1,000 Staphylococcus aureus/g No, in raw food Wash cut, bandage
Prevent toxin production, 3-log
reduction
1 CFU/g from cuts
Bacteria on uniform, hair, fingernails,
jewelry
No evidence of significant risk from
pathogens
No Exclude physical filth to a tolerable
level by following GMPs
The level of filth in the food is
tolerable
Streptococcus from throat; coughing
on food
103 Streptococcus (est.) if cough on food Yes, if food
temperature
>55ºF (12.8ºC),
>4 hours
Cough into shoulder / no droplets on
food
<10 CFU on food when
consumed
Environment / facilities
Water No significant risk if city water No City report of water treatment every 6
months
Water <1 coliform / 100 ml
Pests, flies, rats Contamination of raw food killed by
pasteurization; No evidence of
significant risk to the contamination of
ready-to-eat food in the kitchen
Unlikely Keep kitchen clean; starve out pests No detectable significant
contamination of ready-to-eat
food
Sewage back-up No evidence of significant risk of
sewage water contaminating food
Unlikely Close kitchen if severe back-up No measurable sewage
bacteria in food
Listeria from environmental
contamination
100 Listeria/g from kitchen environment Yes, at >30ºF
(-1.1ºC)
Store,<3-log increase [<7 days, 41ºF
(5ºC)]
<100 CFU/g
Equipment
Cross-contamination on food contact
surfaces transferred to ready-to-
eat food
1,000 Campylobacter spp./g on cutting
board / fingers after touching raw food /
poultry
No After handling / touching raw meat,
fish, and poultry, wash fingers, cutting
board for a 5-log reduction of surface
<10 CFU Campylobacter spp.
on fingers or on 8 square
inches (50 square cm) cutting
board
Supplies
Receiving dented cans; broken /
damaged meat, fish, poultry
packages
Clostridium botulinum in damaged food Possible Reject damaged cans / food No damaged cans / packages
Storage, raw meat, fish, poultry Growth of Salmonella or E. coli or
Listeria monocytogenes
Unlikely Temperature <41ºF, 0ºF (<5ºC,
-17.8ºC); pathogens will be killed with
pasteurization
<1 CFU/25 g highly infective
pathogen
Storage, ready-to-eat food No risk; supplier reduces pathogens to
an Appropriate Level Of Protection
(ALOP) and assures Temperature
Control for Safety (TCS); controls
chemical and physical hazards
No Supplier makes safe <1/25 g highly infective
pathogen
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PREREQUISITE PROCESSES HAZARD IDENTIFICATION
H0 + I - R FSO / ALOP
Environment and facility
• Rodents, insects, birds
• Contaminated water, sewage back-up
• Cross connections, dripping pipes / roof
• Power interruption
• Waste disposal
• Lights, glass, plastic
Equipment, tools, utensils cleaning and maintenance
• Food contact surface smooth
• Safe metal or wood
Personal Hygiene (70% symptomless shedders)
• Feces from toilet on fingers
• Strep throat
• Staphylococcus aureus from skin and infected cuts
• Hair, jewelry
Supplies (stock list)
• Suppliers qualified
• Ingredients, ready-to-eat, raw, chemical,
physical hazards
• Ingredient separation
• Storage; Rh, temperature, time, container
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KITCHEN CLEANING AND SANITATION FOR LISTERIA CONTROL
HAZARD It must be assumed that the kitchen
environment will be colonized with
Listeria monocytogenes (Lm). The food
contact surfaces in the cook-chill
assembly and packaging departments for
ready-to-eat food must be cleaned so that
there is no measurable Lm (<1 CFU / 25
grams of food).
CONTROL 1. Determine the niches in the equipment in the ready-to-eat assembly and packaging areas where Lm might
become colonized.
2. Establish a cleaning plan for this area.
3. Chose a control alternative
a. Add a Lm chemical growth inhibitor such as sodium diacetate or potassium lactate and also, do a post-
package heat treatment.
b. Just add the chemical inhibitor.
c. Use sanitation measures only. This is the best for retail, because it does not affect the product.
VALIDATION: Monthly, take 1 to 3 sponge samples of food contact surfaces and 1 to 3 samples of environmental surfaces
(e.g., floor drains, scrubbies, floor scrubbers) and test for Listeria innocua. Can composite samples. Follow the action flow chart,
FSIS Dir 10,240.3.
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HAND WASHING HACCP
Hazard: Toilet paper slips and tears, and a person can get
6 log fecal pathogens on fingertips.
Control (gloves or the following): When coming from the toilet, do the double wash
with a nail brush for a 6 log reduction by dilution.
1. Nail brush friction, detergent, and warm water,
3 log reduction
2. Second wash, no nail brush, 2 log reduction
3. Paper towel dry, 1 log reduction
4. Water flow, no splash, 2 gallons (7.6 liters) /
minute
5. No touch controls are not necessary
Validation: 1. Contaminate fingertips 7 log with non-
pathogenic E. coli ATCC 25922
2. Double fingertip wash, 6 log reduction
3. Petrifilm™ recovery E. coli <10 total
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FOOD CONTACT SURFACE WASHING HACCP (cutting boards, knives)
(120 F = 48.9 C 75 F = 23.9 C 171 F = 77.2 C)
Hazard: Campylobacter jejuni from chicken
(1,000 to 10,000 on surface) and Vibrio
from seafood; scarred surface not a risk
Control: 1. With warm water running over the
cutting board into a disposal, scrub
with a brush for a few seconds;
3 log reduction by dilution
2. In the pot and pan sink, scrub again;
2 log reduction by dilution
3. Rinse to remove soap
4. Sanitize (not a CCP), air dry
Validation: 1. Put 7 log E. coli on the cutting board
2. Wash and sanitize
3. Swab 50 sq cm (8 sq in), <100 E. coli,
5-log reduction
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PREREQUISITE SANITATION MANAGEMENT PLAN Significant risk, vegetative pathogens transfer to ready-to-eat food
SCHEDULE Equipment / Area / Surface Frequency Chemical
Installed equipment: cleaning; calibration
Hoods
Sinks / faucets
Walk-in refrigerators
Blast chill refrigerators
Thaw cabinets
Walk-in freezers
Reach-in refrigerators
Reach-in freezers
Display refrigerators
Display freezers
Lights
Water baths
Carts (wheels)
Cooking equipment
Ovens, broilers, fryers
Hot holding cabinets
Steam tables
Washing machines
Dish and pot wash machines
Smallwares
Small utensils
Cutting boards
Cooking utensils and equipment
Hotel pans
PROCESS
MAPLE WOOD CUTTING BOARD
Get ready
3-compartment sink filled as follows:
1st sink: (dishsoap) solution
2nd
sink: rinse water
3rd
sink: (sanitizer) solution
Food scraper
Scrub pad and scrub brush
Action
1. Remove cutting board every 4 hours or more often, and take
to 3-compartment sink to be cleaned.
2. Scrape loose food particles into disposal.
3. Using scrub brush, wash board with (dishsoap) solution in
first sink.
4. Rinse in clean, warm water in second sink.
5. Sanitize in 3rd
sink, 1 minute, 50 ppm chlorine.
6. Allow to air dry.
Check that cutting board is clean.
All food is removed.
Boards are free of nicks in wood.
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MICROBIOLOGICAL SAMPLING
Conponents:
Petrifilm™ AC plates (20 sq cm / 3 sq inches) /
E. coli plates
Letheen broth tubes (sanitizer neutralizer)
Cotton swab
1-ml pipettes
Spreader plate
Uses:
Surface cleanliness sampling
(50 sq cm / 8 sq inches) (swab)
Surface sampling (direct contact)
Food: APC, Staphylococcus aureus,
coliform / E. coli, Listeria monocytogenes
Classroom: fingers, hair
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SAMPLING THE pH OF FOOD
Method: Calibrate with pH 4.01 and pH 7.01 buffer. Put
probe in stirred sample, 20 C. Wait 30 seconds for
stable reading.
ACIDS THAT CAN BE USED
Acid pKa Examples of usage
Acetic acid 4.75 Pickling of meat, fish, and vegetable
products
Sodium
diacetate
4.75 Bread and bakery products
Sodium
benzoate
4.2 Pickles, acid sauces and salads, semi-
preserved fish, fruit juices, soft drinks,
jams, margarines
Citric acid 3.1 Soft drinks
Lactic acid 3.1 Salad creams and mayonnaise
Methyl parabena 8.5
Ethyl parabena 8.5 See sodium benzoate
Propyl parabena 8.5
Sodium
propionate
4.9 Breads, bakery, and cheese products
Sorbic acid
(including
potassium salt)
4.8 Fresh and processed cheese, dairy
products, bakery products, fruit juice,
acid sauces and salads, jams, jellies,
soft drinks, margarines, semi-
preserved fish and meat products a Paraben = p-hydroxybenzoic acid
Reference: ICMSF, 1980. Microbial Ecology of Foods. Vol. 1. Factors affecting
growth and death in microorganisms. 128-129. Academic Press, New York, N.Y.
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MENU INGREDIENT HAZARD INVENTORY
Supplier Makes Safe (ready-to-eat) Cook Makes Safe (raw)
Potatoes, cooked
Onion Rings, cooked
Corn Beef Hash, cooked
Sausage Links,
precooked
Cheese Pizza, fully
cooked
Turkey Breast, fully
cooked
Nacho Meat
Roast Beef
Kraft Macaroni and
Cheese
French Toast Batter
Gravies (pasteurized
ingredients)
Soups
Marinara Sauce
Oatmeal
Vegetables, frozen
Coleslaw Mix
Canned Fruits
Applesauce
Cheeses
Pickles
Cocktail Sauce
Butter
Honey
Salad Dressings
Condiments
(e.g., ketchup)
Coffees
Fruit Juices
Soft Drinks
Milk
Bread Products
Apple Crisp
Frozen Pies
Cakes
Ice Cream
Jams and Jellies
Vinegar
Sugar (brown,
powdered)
Potato to be baked
Chicken parts and strips
Chicken Fried Steak
Cod, battered
Shrimp, breaded
Bacon
Hamburger, Junior and
Regular
Eggs (in-the-shell)
Steak
Country Fried Steak
Fresh Vegetables
Fresh Fruits
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HOW DO YOU KNOW IF FOOD IS HAZARDOUS OR SAFE?
You control the process.
Food Spoilers Do not cause illness.
Change the flavor, odor, and appearance of food.
Inhibit growth of pathogens.
Food Process "Spoilers"? Used in the production of food products
(e.g., vinegar, bread, sauerkraut, cheese).
They "spoil" the food.
Food Pathogens Cause illness.
Often do not change the flavor, odor, and appearance
of food to indicate that the food is hazardous.
If in doubt about how food was handled after cooking,
throw it out.
854/1901
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MENU ITEM HAZARD CONTROL PLAN
Menu Item Storage Preparation Hold / Serve Leftovers
Steak, sirloin /
steak T-bone, raw
Frozen / thaw 24 hrs.
refrig. Hold 48 hrs. / RD
<40ºF (<4.4ºC) (clock
date).
Cook to order >145ºF (>62.8ºC), CCP
unless customer requests otherwise.
Serve
immediately. None
Eggs, pasteurized
liquid, supplier
pasteurized
After opening 24 hrs. /
WR <40ºF (<4.4ºC) (clock
date).
Cook to order (scrambled eggs, omelets) to
>150ºF (>65.6ºC), 15 sec.
Serve
immediately. None
Eggs, fried, raw Refrigerated shell eggs
[<40ºF (<4.4ºC)].
Cook to 145ºF (62.8ºC), 15 sec., unless
customer requests otherwise. CCP.
Serve
immediately. None
Eggs, hard boiled,
raw
Refrigerated shell eggs
[<40ºF (<4.4ºC)].
Cook for 10 minutes, >150ºF (>65.6ºC), 15
sec. Pour ice over eggs to cool. CCP.
24 hrs. refrig.
<40ºF (4.4ºC). Discard
Oatmeal, aw
control, supplier
pasteurized
RT storage
Mix pack with hot water [>190ºF (87.8ºC)]
or: Kettle, add oatmeal to boiling water,
simmer 8-10 minutes <160ºF (71.1ºC), 15
sec.
Service
immediately.
ST = 4 hrs.,
>160ºF (71.1ºC)
Discard
Mashed potatoes,
aw control, supplier
pasteurized
RT storage
Mix 2 qts. (1.8 liters) boiling water [212ºF
(100ºC)], 2 oz. (60 ml) Liquid Margarine
and 1 bag potato mix >160ºF (71.1ºC), 15
sec.
Service
immediately.
ST = 4 hrs.,
>160ºF (71.1ºC)
Discard
Celery, raw
5 days refrig. <40ºF
(4.4ºC) (cover label, clock
date).
Clean and trim. Double wash. CCP. Cut or
dice <40ºF (4.4ºC).
<40ºF (4.4ºC),
24 hrs. Discard
Lettuce, iceberg,
raw
5 days refrig. <40ºF
(4.4ºC) (cover label, clock
date).
Clean, core, remove brown leaves. Double
wash. CCP. Quarter. Separate leaves.
Remove excess water. Store in plastic
container <40ºF (4.4ºC).
<40ºF (4.4ºC),
24 hrs. Discard
RD = refrigerated drawer WR = walk-in refrigerator RT = room temperature FD = freezer drawer
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FOOD PROCESS PERFORMANCE-BASED DESIGN FOR SAFETY (cont'd)
Risk Factors (hazard source)
H0 (incoming hazard level)
+I (increase)
-R (reduction / control)
FSO (output)
Food Production
Thaw No significant Salmonella / E. coli
growth during thaw
Not significant,
<1 log
5-log pasteurization
No toxin production
Pasteurization reduces
vegetative pathogens to
<1 CFU/25 g
Pre-preparation
(Staphylococcus aureus not a problem,
because spoilage organisms out-
compete microorganisms and
prevent growth)
Vegetative pathogens:
1,000 Salmonella / E. coli/g
<1-log
multiplication
Wash for a 2-log reduction; 5-log
reduction cannot be achieved
FSO of 1 CFU/100 g is
desired
Preparation 1,000Salmonella / E. coli/g No 5-log pasteurization 1/25 g highly infective
Hot hold Spores:
100 Clostridium perfringens/g
survive pasteurization
<1-log increase
vegetative
Clostridium
perfringens
Temperature >130 F (54.4ºC) prevents
germination
<10/g increase
FSO <5 log/g
Cool 100 Clostridium perfringens spores/g <1,000 CFU / gram
increase
Cool to prevent >3-log increase in
Clostridium perfringens vegetative cells
<5 log Clostridium
perfringens vegetative cells/g
Cold hold 100 Bacillus cereus spores/g <1,000 Bacillus
cereus increase
during cold hold
Hold at a time and temperature to
prevent >3-log increase of Bacillus
cereus
<5 log/g
No detectable toxin
Reheat
(not necessary if control steps have
been followed)
<5 log Bacillus cereus and
Clostridium perfringens/g; no
significant risk; prevent cross-
contamination to ready-to-eat food
(hands are washed)
Prevent toxin by Staphylococcus
aureus
No Reheating to 165ºF (73.9ºC),
15 seconds will reduce vegetative
pathogens to safe level (toxin
prevented)
FSO <10/g
No detectable toxin
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GROWTH OF BACTERIA IN FOOD BASED ON FDA FOOD CODE HOLDING / STORAGE
RECOMMENDATIONS
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
0 20 40 60 80 100 120 140
Temperature (oF)
[1/g
en
era
tio
n (
h)]
1/2
25
100
Tim
e (h
ou
rs)
11.1
6.3
4.0
2.8
1.6
1.2
1.0
0.69
0.83
0.59
0.5
0.4
2.0
HITM - adapted FDA Food Code
y = 0.032*(temp oC -(-2.924))*
(1-Exp (0.444 *(temp oC - 52.553)))
Spoilage bacteria
y= 0.016x-0.2969
Bacterial Pathogens
y = 0.015x-0.4364
spoilbac/Chart9
Temp.
C ( F) 1
Generation 10 Generations / 3-log increase
-1.1 (30) 297.14 hr. 123.8 days
1.7 (35) 46.34 hr. 19.3 days
4.4 (40) 17.99 hr. 7.5 days
5.0 (41) 15.55 hr. 6.5 days
7.2 (45) 9.49 hr. 4.0 days
10.0 (50) 5.85 hr. 2.4 days
12.8 (55) 3.96 hr. 1.7 days
15.6 (60) 2.86 hr. 1.2 days
21.1 (70) 1.69 hr. 16.9 hr.
26.7 (80) 1.12 hr. 11.1 hr.
32.2 (90) 0.79 hr. 7.9 hr.
37.8 (100) 0.59 hr. 5.9 hr.
43.3 (110) 0.47 hr. 4.7 hr.
46.1 (115) 0.46 hr. 4.6 hr.
48.9 (120) 0.56 hr. 5.6 hr.
41.7 (125) 3.10 hr. 31.0 hr.
1382
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FOOD RECEIVING AND STORAGE HACCP
Hazard: Pathogens from raw food can cross-contaminate
ready-to-eat food.
Control:
Raw food: time and temperature not CCP;
washing or cooking makes food safe
Ready-to-eat food on top, raw on bottom
Air flow: 5 feet (15 meters) per minute
holding; 1,000 feet per minute cooling;
41ºF (5 C), 7 days; 45ºF (7.2 C), 4 days; 50ºF
(10 C), 2.5 days; 70ºF (21.1 C), 18 hours; 110ºF
(43.3 C), 4 hours
Humidity 70% to prevent mold growth; 95% to
prevent drying of fruits and vegetables
Validation of temperature:
Cup of salt in refrigerator and freezer
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WASHING AND BLANCHING FRUITS AND VEGETABLES (VEGETATIVE BACTERIA) HACCP
71ºC = 160ºF
Hazard: Raw fruits and vegetables are contaminated in the
pores of the surface. Chemicals do not affect
pathogens in the surface.
Control: The bacteria must be removed by brush friction or
water turbulence. The following reduces bacteria,
parasites, and viruses about 2 log by dilution.
1. Trim.
2. Wash in turbulent water. Transfer to 2nd sink.
3. Rinse in turbulent water, 2nd sink.
4. Spin dry.
Chemicals can be used in a 3rd sink, but have a
limited effect, 1 log.
Blanch fruit or vegetable in 160ºF (71 C) water,
1 minute, for a 5-log reduction.
Validation: Put E. coli on food and measure before and after
treatment, using E. coli Petrifilm™.
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THAWING
Flowing water <70ºF (<21.1ºC)
Refrigerator <41ºF (<5ºC) Below cooked food, uncovered
Microwave When followed by immediate cooking
Cook from the frozen 1/3 more time Roast beef, turkey, steak, hamburger,
prepared food
HACCP validates thawing on the counter as safe. At 70ºF (21.1ºC), air thawing takes about 11 to 12 hours for a 25-lb (11.34 kg) turkey. The surface gets to about 55 to 60ºF (13 to 16ºC), and there is approximately 1 multiplication of Salmonella.
1228
Klose, A.A., Lineweaver, H., and Palmer, H.H. 1968. Thawing turkeys at ambient air temperatures. Food Technol. 22: 1310-1314.
(41º=5ºC)
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TEMPERATURE MONITORING that the process is in control
Bimetallic Coil Thermometer = Average temperature over 7.6 cm (3 inches) (from tip to dimple)
Thermocouple [1 mm (0.040-inch) diameter or less] = Temperature at tip
Thermistor [1.6 mm (0.0625-inch) diameter] = Average temperature from tip up 0.6 cm (0.25 inch)
Infrared Heat Detector = Surface measurement 1261
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DESTRUCTION OF SALMONELLA IN FOOD
1326
DEATH CONTROLS
Time and temperature Nutrients and acids Water activity Color not reliable
DESTRUCTION OF SALMONELLA SPP. IN FOOD
Temp.
F ( C)
5D FDA Hamburger (100,000:1)
6.5D FDA Roast beef
(3,160,000:1)
7D USDA Poultry
with 12% fat
130 (54.4) 86 min. 112 min ---
135 (57.2) 27 min. 35 min. ---
140 (60.0) 8.7 min. 11.2 min. 35 min.
145 (62.8) 2.7 min. 3.5 min. 13.8 min.
150 (65.6) 52 sec. 67 sec. 4.9 min.
155 (68.3) 16 sec. 21 sec. 1.3 min.
160 (71.1) 5.2 sec. 6.7 sec. 26.9 sec.
165 (73.8) Instant Instant <10 sec.
1326
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FOOD PASTEURIZATION HACCP (VEGETATIVE BACTERIA)
Hazard: Pathogens contaminate raw meat, fish, and
poultry.
Control: Salmonella is the target pathogen.
Reduce Salmonella 5 log / 7 log.
(Assumes the food is contaminated with about
1,000 / gram, and must be reduced to
1 per 100 grams.) Color not reliable.
Validation:
Contaminate with non-pathogenic E. coli.
Take sample before heating, <68ºF
(<20 C).
Take samples about 130ºF, 140ºF, and
150ºF (55 C, 60 C, and 65 C). By 150ºF
(65 C), there should be >5-log reduction.
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THE SEVEN COOK-THEN-PACKAGE / SERVE RECIPE PROCESSES Kill the Salmonella and do not let the spores multiply.
1284
350ºF = 177ºC 225-275ºF = 107-135ºC 250-400ºF = 121-204ºC
35ºF = 1.7ºC 200ºF = 104ºF 212ºF-250ºF = 100-121ºF 75ºF = 24ºC
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FOOD GROUPS HACCP PROCESS ANALYSIS
HACCP Process Groups
(USDA HACCP, 9 CFR 417) Prerequisite / GMPs working
Control Shelf life
I Raw, not heat treated. Not TCS / no RPG: sprouts; raw meat,
fish; sushi, sashimi; eggs, raw fruits and vegetables, flour, salt,
sugar, spices, oil
Grown safe, with H0 that meets FSO.
May require Temperature Control for
Quality.
<14 days or
longer
(bact. spoilage)
II Not fully cooked, with inhibitors to make shelf stable.
Water activity: nuts, sugar icing, butter honey, dried fish, fresh
pasta, peanut butter
Fermentation: pepperoni, salami; olives; dairy (cheese,
yogurt, sour cream / milk / crème fraîche); bread; sauerkraut;
kimchee; beer, wine
Acidified: salad dressing; cole slaw; salsa; condiments
With H0 that, with + I- R (5-log
Salmonella reduction), meets FSO.
Does not require TCS because of
product aw, pH, or additives.
Aw <0.86 (Staphylococcus)
pH <4.2 (Salmonella)
(or fermentation)
>2 years, 68ºF
(20 C) (chem.
spoilage)
III Fully cooked, not shelf stable. hot or cooled, refrigerated
ready-to-eat food; meat, fish, poultry; fruits, vegetables, dairy,
pastry filling, pudding
Pasteurized (5-log to 7-log
Salmonella) so that + I- R meets
FSO.
Requires TCS.
41 to 135ºF (5.0
to 57.2 C), 4
hours or
Cold 41ºF
(5.0 C), 7 days /
unlimited
IV Fully cooked, with inhibitors to make shelf stable. marinara
sauce; fruit pie fillings; cake icing, bread and pastry, dry
cereals, dry pasta, smoked fish; packaged, low-pH fruits and
vegetables
Pasteurized (5-log to 7-log
Salmonella) so that + I- R meets
FSO.
Aw <0.92; pH <4.6
Does not require TCS because of
product aw, pH, or additives.
>5 years
V Commercially sterile, shelf stable. "packaged" meat, fish,
poultry, fruits, vegetables, dairy / UHT milk
Sterilized, Clostridium botulinum
spores reduced 9 log to 12 log.
Does not require TCS.
>5 years
PHF=Potentially Hazardous Food; RPG-Rapid and Progressive Growth; UHT=Ultra High Temperature; Ho=Starting Hazard;
FSO=Food Safety Objective; =summary; I=Increase; R=Reduction; TCS=Temperature Control for Safety; aw=water activity
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RETAIL PROCESS HACCP BASED ON FIVE USDA HACCP PROCESSES
Process Purchase Receive /
Store Pre-Prep Preparation
Transport, Hold, Serve
Cool Customer
Consumption
I. Not heat treated, not shelf
stable
Raw mushrooms, green onions,
salad greens, fruit, fruit juice,
fresh fruit and vegetable salads,
fish, beef, pork, shellfish, eggs
CCP. Farmer has
HACCP and
guarantees safe
levels of hazards
on food.
No B,C,P
cross-
contamination
Remove hard foreign
objects.
Wash fruits and
vegetables, 2 log.
No cross-
contamination.
No B,C,P cross-
contamination.
No B,C,P
cross-
contamination.
N/A Raw food spoils
safe.
No B,C,P cross-
contamination.
II. Not heat treated, with
inhibitors to make shelf stable
Combine flour, nuts, salt, sugar,
vinegar, eggs, milk, etc. to make
foods such as butter with honey,
herbs, acid, salad dressing,
pickles, olives, kimchee, wine.
CCP. Farmer /
supplier has
HACCP and
guarantees safe
levels of hazards
on food.
No B,C,P
cross-
contamination
Remove hard foreign
objects.
Wash fruits and
vegetables, 2 log.
No cross-
contamination.
CCP. 5-log
Salmonella kill with
acid if eggs added
or pH <4.1 or aw
<0.92 or
combination.
No hazard. No hazard. No hazard.
III. Fully cooked*, not shelf
stable
Ready-to-eat meat, fish, poultry,
butter, cheese, ice cream, salads
with cooked safe ingredients
<103 Salmonella.
Chemicals at
tolerable levels.
No C,P cross-
contamination.
Remove hard foreign
objects.
CCP. Cooking
gives a 5-log to 7-
log Salmonella kill;
spores survive. No
inhibitors.
CCP. >130ºF
(54.4ºC).
CCP. <14
hours, 120 to
55ºF (48.9 to
12.8ºC).
CCP. <40ºF
(4.4ºC) or <3 log
growth of
vegetative
pathogens before
consumption.
IV. Fully cooked*, with
inhibitors to make shelf stable
Smoked, salted, canned meat,
fish, poultry; canned fruit; jam,
jelly, syrup, processed cheese,
acidic sauces (BBQ sauce,
catsup), acidic beverages, bread,
bagels, cake, cookies, dry cereals,
taco shells)
<103 Salmonella.
Chemicals at
tolerable levels.
No C,P cross-
contamination.
Remove hard foreign
objects.
CCP. Cooking
gives a 5-log to 7-
log Salmonella kill.
pH, aw , and
chemical inhibitors
prevent spore
outgrowth.
No hazard. No hazard. No hazard.
V. Commercially sterile**, shelf
stable
Hermetically / anaerobically
packaged food (vegetables,
beans, meat, poultry, fish, soup,
dairy products)
<1 Clostridium
botulinum / gram
Chemicals at
tolerable levels.
No C,P cross-
contamination.
Remove hard foreign
objects.
CCP. Product
receives a 9-log to
12-log Clostridium
botulinum
reduction.
No hazard. No hazard. No hazard.
B,C,P = biological, chemical, and physical Not shelf stable = pathogenic vegetative cells can grow, and spores can outgrow
*Fully cooked = 5-log to 7-log Salmonella treatment or Food Safety Objective (FSO) of <1 Salmonella / 25 grams
**Commercially sterile = 9-log to 12-log Clostridium botulinum treatment
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CHICKEN CACCIATORE QA RECIPE FLOW AND QUALITY-ASSURED HACCP RECIPE PROCEDURES
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FOOD HOT HOLD HACCP (SPORE CONTROL)
Hazard:
The surface of food with a center
temperature of 140ºF (60 C) in a steam
table exposed to air with a relative
humidity of 50% will be about 117ºF
(47.2 C) because of evaporative cooling.
Clostridium perfringens will grow <125ºF
(<51.7 C). Hot hold >125ºF (>51.7ºC).
Heat lamps dry food.
Control: Keep food covered; keep high humidity,
>90%, above food; or cover food with
something like a butter sauce or cheese.
Validation:
Make a pan of instant mashed potatoes with
cooked ground beef and C. perfringens on
the surface.
Measure temperature. Hold in a steam table
for 4 hours. Measure C. perfringens
growth.
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FOOD COOLING HACCP (SPORE CONTROL)
Hazard: Clostridium botulinum, Bacillus cereus, and
Clostridium perfringens spores will germinate and
multiply if cooling is too slow between 125 and
80ºF (51.7 and 26.7 C).
Control:
Cool fast enough between 120 and 80ºF (48.9
and 26.7 C) to prevent outgrowth of spores <1
log.
Pre-cool to 120ºF (48.9ºC) at room temperature.
Blast cooler 300 meters per minute air, 38ºF
(3.3 C), 2-inch (5-cm) pan, 6 hours.
Ordinary reach-in refrigerator 50 feet
(15 meters) per minute air, 2-inch (5-cm) pan,
15 hours.
Validation:
Cook hamburger to 158ºF (70 C) to pasteurize
the food and activate the spore. Put in a test
container.
Cool. Take a center sample before and after
cooling. Determine if there is growth.
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COOLING TIMES AND TEMPERATURES
FDA 6-Hour Cooling
57.2 to 5.0 C (135 to 41ºF)
[3.3 C (38ºF) Environment]
USDA Cooling
48.9 to 12.8 C (120 to 55ºF) in 6 hours, followed by cooling to
4.4 C (40ºF)
[3.3 C (38ºF) Environment]
Hr. C ( F) Hr. C ( F)
0 57.2 (135) 0 48.9 (120)
1 34.4 (94) 1 38.3 (101)
2 21.1 (70) 2 30.0 (86)
3 13.2 (55.8) 3 23.9 (75)
4 48.9 (8.0) 4 18.9 (66)
5 6.39 (43.5) 5 15.6 (60)
6 5.0 (41) 6 12.8 (55)
7 10.6 (51)
8 8.9 (48)
9 7.5 (45.5)
10 6.61 (43.9)
11 5.83 (42.5)
12.6 5.0 (41)
14.16 4.4 (40)
1342
COOLING FOOD FROM 48.9 TO 12.8 C (120 TO 55ºF) IN 6 HOURS (USDA GUIDELINES) COMPARED TO FDA 6-HOUR COOLING
RECOMMENDATION
pictures:cooling-USDA-FDA-addedpoint-2-15-11
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RAPID COOLING METHODS 6 HR. TO 5 C (41ºF) (FDA) 48.9 TO 12.8 C (120 TO 55ºF), 6 HR. (USDA)
915
32 F = 0 C
35 F = 1.7 C
190 F = 87.8 C 1,000 ft = 300 meters 50 ft = 15.25 meters
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BUFFETS – BANQUETS
Hazard Analysis
Customer sneezing Staphylococcus or
Streptococcus on food.
Not a significant risk, because bacteria must
multiply to an infectious does, and the food is
thrown out first.
Customer getting fingers in food.
Not significant, because not enough
pathogens are transferred.
Customer cross-contaminating allergens.
This is possible, but highly unlikely.
Customer cross-contamination if customer
does not use clean plate and utensils.
Not a significant risk, because there are too
few pathogens to be an infective dose, and
mouth bacteria are not a significant risk.
872
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THE RETAIL FOOD SAFETY MANAGEMENT SYSTEM WITH PROCESS PERFORMANCE STANDARDS
1. Management
7. Food HACCP processes
Process Safety Objectives / performance standards
Biological, Chemical, and Physical Hazards
Controls: Prevent, Eliminate, Reduce
+ Increase - Reduction pathogen substance
Physical hazards: eliminate, reduce <1/16 inch (1.6 mm)
Fruits and vegetables: wash 2-log or surface blanch 5-log reduction
Pasteurize (in package or not) 150ºF (65.6ºC) for 1 minute for 5-log Salmonella reduction
Additives / dry shelf stable
Sterilize 250ºF (121.1ºC) for 3 minutes for 12-log Clostridium botulinum reduction
Hot hold >130ºF / 135ºF (>54.4ºC / 57.2ºC), <1-log increase Clostridium perfringens
Cool <2-inch (5-cm) pan , <6-inch (15.24 cm) diameter pot, <1-log Clostridium perfringens multiplication
Cold hold <41ºF (5ºC), <1-log spore / vegetative cell multiplication
Acidify, shelf stable pH <4.2 Salmonella, <5.0 Bacillus cereus, <4.6 Clostridium botulinum
Water activity, shelf stable <0.86 Staphylococcus aureus, <0.92 Bacillus cereus
pictures&00lh2: retail fd sys house-4-10
INPUT Baseline hazards H0
Prerequisite Processes
Daily Operations
Report
2. Personnel
Double wash, nail brush
6-log reduction
3. Environment
Pest prevention ; Water
4. Facilities
5. Equipment
Pest prevention; Food
contact surface wash
5-log / 2-log reduction
6. Supplies
Food that the farmer grew /
processor made safe; Prevent
cross-contamination /
allergen identification,
separation; Chemical
separation, control
8. Products
and Services
Customer abuse:
Eat before 1-log
increase of spore /
vegetative cell
multiplication or
refrigerate
immediately
Cook, package,
store, serve later
OUTPUT FSO /
ALOP / TLR
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EMPLOYEE FOOD HACCP TRAINING CHECKLIST
PREREQUISITES Personal hygiene
If I have vomiting or diarrhea, I will tell the PIC.
I will double wash my fingertips when coming
from an "unknown location" such as the toilet.
When handling raw meat / fish / poultry, I will
clean my hands and food contact surface before
touching RTE food.
I do not touch my skin when working with food.
Immediately after glove use, I remove the gloves
and wash my hands
Receiving
When receiving food / opening food, any food that
is damaged or spoiled will be returned to the
supplier / discarded. Refrigerate food 41ºF
(5ºC).
Storage
I store raw food on the bottom shelves in the
refrigerator and RTE food above the raw food.
I store chemicals completely separate from food.
Equipment
I assure that my equipment is clean before I use it.
I assure that my equipment is working correctly
and calibrated before I begin preparation.
FOOD PROCESS HAZARD CONTROLS I double wash raw fruits and vegetables before using in menu
items.
During pre-preparation, I remove physical hazards from food.
I know if any ingredient in a recipe is an allergen so that I can
accurately answer customer questions. If in doubt, I refer
allergen questions to the kitchen manager.
After handling raw meat / fish / poultry, I decontaminate my
hands, equipment, and work area before touching ready-to-
eat food.
I know how to use a thermometer or thermocouple properly.
I cook foods to the following center temperatures:
a. Solid steaks, chops, fish: 145ºF (62.8ºC), 15 seconds
b. Ground meat, fish: 155ºF (68.3ºC), 15 seconds
c. Poultry: 165ºF (73.9ºC), 15 seconds
OR: as ordered by the individual customer.
I hold hot food 135ºF (57.2ºC) or hotter, or for less than 4 hours
if time is used as a control.
When cooling, I place no more than 2 inches (5 cm) of solid
food in a pan, no more than 1 gallon (4 liters) of liquid in a
container.
When making a cold combination such as salads, I pre-cool
ingredients to 50ºF (10ºC) or colder. When mixing, I wear
gloves or use a utensil.
I hold cold ready-to-eat food at 41ºF ( ºC) or colder for no more
than 7 days. It is labeled.
I do not add leftovers to a fresh food.
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WEEKLY HACCP CHECKLIST
Evaluator _____________________________________ Date ____________________ Time ___________________
PREREQUISITE HACCP REQUIREMENTS PERSON / ITEM : OBSERVATION CORR.
ACT #
1. Personal Hygiene
(Person: Health, cleanliness, double hand washing when coming from toilet, single
hand washing for raw food / RTE food control, gloves control)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________ 3. __________________ : _____________________________________________
2. Environment / facilities
(Item: Cleaned, maintained, pests, trash, chemicals, water, plumbing controlled)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________ 3. __________________ : _____________________________________________
3. Equipment
(Item: Cleanliness, temperature, maintenance, sanitizer concentration, thermometers /
instrument calibration)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________ 3. __________________ : _____________________________________________
4. Supplies
(Food: temperature, use by; inventory rotation; approved supplier, protected, RTE on
top)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________ 3. __________________ : _____________________________________________
FOOD HACCP PROCESSES FOOD : OBSERVATION CR ACT#
1. Physical hazards
(Food: hard foreign objects, choking, thermal)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________
2. Chemical hazards
(Item: separate from food, used at correct level)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________
3. Allergen control
(Food: allergen control; do not add fresh to old; do not combine different leftovers
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________
4. Double wash fruits and vegetables
(Food: adequate physical wash)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________
5. Cooking pasteurization
(Food: temperature and time, pH, water activity)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________ 3. __________________ : _____________________________________________
6. Hot hold, transport, serve / catering
(Food: temperature 135ºF / 57.2ºC hold time, surface humidity)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________ 3. __________________ : _____________________________________________
7. Cooling (<2 inches thick, <1 gallon / <5 cm thick, 4 liters)
(Food: container, date)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________ 3. __________________ : _____________________________________________
8. Cold hold, transport, serve / catering
(Food: temperature, protection)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________ 3. __________________ : _____________________________________________
9. Salads mixed with cold ingredients
(Food: temperature)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________
10. Leftovers
(Food: temperature, age, refrigeration, freezing)
1. __________________ : _____________________________________________ 2. __________________ : _____________________________________________
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PROCESS VALIDATION / VERIFICATION SUMMARY
Validation / Verification Procedure
1. Recipe
2. Flow the process
3. Get process performance values and critical limits
4. Do challenge tests to validate that performance standards can be met
Validation Standards
To validate refrigerated holding processes, use non-pathogenic Listeria innocua and control to <3-log increase.
To validate washing food contact surfaces and pasteurization, use non-pathogenic E. coli ATCC 25922 and
measure reduction.
Reduction on fingertips after using the toilet, 6 log.
Reduction on fingertips after touching raw meat, fish, and poultry, 2 log.
Reduction on raw food contact surfaces, 5 log.
To validate cold holding of ready-to-eat food, use a non-pathogenic Bacillus cereus and control to <3-log
increase.
To validate cooling, use non-pathogenic Clostridium perfringens and limit to 1-log increase.
Once you have a validated process, you do not have to log it all of the time.
You just have to verify that you are doing the process according to the validated process.
Washing for a 5-log surface reduction of Salmonella
Washing fingers for a ≥5-log Salmonella reduction
Washing ready-to-eat vegetables for a ≥5-log E. coli reduction
Pasteurizing for a ≥5-log Salmonella reduction
Hot hold for a <1-log Clostridium perfringens increase
Cooling for a <1-log (3-log) increase of Clostridium perfringens
Cold holding for a <3-log increase of Listeria monocytogenes
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RETAIL FOOD PROCESS GOVERNMENT SAFE HARBORS VS. HACCP
Process step: FDA safe harbors control HACCP analysis
Receiving
Raw, aerobic fruits and vegetables:
No pathogen growth control
None necessary; spoil safe
Shelf-stable canned food:
None; canning makes safe
None necessary; canning makes safe
Frozen meat, fish & poultry:
Frozen; no specified temperature, <-1.1 C (30 F)
<-1.1 C (30 F) is safe; no growth
Raw meat, fish & poultry:
5.0 C (41 F); no time limit
Cooking gives adequate reduction
RTE refrigerated meat, fish and poultry from vendor:
5.0 C (41 F); no time limit (supplier use-by-date)
Supplier reduces vegetative pathogens to a safe level
RTE bagged vegetables from vendor:
5.0 C (41°F); no time limit
Clostridium botulinum control
Spoilage bacteria grow fastest and spoil food
Pre-preparation
Cut-up fruits and vegetables, raw meat, fish, poultry, RTE
food:
None
Cooking gives adequate reduction
Wash fruits and vegetables:
None
Desired 5 log E. coli reduction
Freeze fish, Anisakis control:
-20 C (-4 F), 7 days
3-log parasite reduction
Cooking
Time to heat food from cold to 54.4ºC ( 130 F):
None
<2 hr. Clostridium perfringens or 12 hr. and pasteurize
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RETAIL FOOD PROCESS GOVERNMENT SAFE HARBORS VS. HACCP (cont'd)
Process step: FDA safe harbors control HACCP analysis
Pasteurization
Whole roasts (beef, corned beef, lamb, veal, pork):
55 C (130 F), 112min.
60 C (140 F), 11.2 min.
65 C (150 F), 1.12 min. (67 sec.)
70 C (157 F), instantaneous
6.5 log Salmonella spp. kill
Solid chops, steaks, fish, farm-raised game animals:
63 C (145 F), 15 sec., and surface browning
Parasite reduction to safe level in center of food
Ground meat and fish:
63 C (145 F), 3 min.
65 C (150 F), 1 min.
68 C (155 F), 15 sec.
70 C (157 F), Instantaneous
5 log Salmonella spp. kill
Poultry, wild game animals, stuffed meat, fish, poultry, pasta
and stuffings containing fish, meat or poultry:
74 C (165 F), 15 sec.
7 log Salmonella spp. kill
Any meat, fish, or poultry cooked in a microwave oven:
74 C (165 F) Stir and hold 2 min.
7 log Salmonella spp. kill
Hot Hold
Hot hold: Whole roasts (beef, pork, corned beef, lamb, veal):
55 C (130 F) No time limit
<1 log growth, C. perfringens
Hot hold: All other food:
57 C (135 F) No time limit
<1 log growth, C. perfringens
Cool
Cool food [(<5 cm (<2 inches) deep, <4-liter (<1-gallon)
container]:
57 to 20 C (135 to 70 F), 2 hr., followed by 20 to 5 C (70 to
41 F) in 4 hr.
<1 log increase of C. perfringens
presentations: Dubai2011: Valid-processes-Mar2-wksp orig 1/28/11 rev 2/11/11 print 2/15/2011 12:06 PM 46
RETAIL FOOD PROCESS GOVERNMENT SAFE HARBORS VS. HACCP (cont'd)
Process step: FDA safe harbors control HACCP analysis
Time as a public health control
Display in the range of 57 to 5 C (135 to 41ºF) without
temperature control:
4 hours, no leftovers
<1 log increase of C. perfringens
Display in the range of 5 to 20 C (41 to 70ºF) without
temperature control:
6 hours, no leftovers
<1 log increase of B. cereus
Cold hold
Holding cold food that requires TCS:
5 C (41 F), <7 days
<1 log increase of B. cereus or <3 log increase L.
monocytogenes
Reheating
Reheat food:
<2 hours from cold to 74 C (165 F) for 15 sec.
No limit on number of times reheated; not a CCP; toxin not
destroyed
RTE = Ready-to-Eat TCS = Temperature Control for Safety
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RETAIL FOOD SAFETY MANAGEMENT: EVIDENCE OF ACTIVE MANAGERIAL CONTROL
Description of Food Safety Operating Procedures for System Operation
Please provide, after each requirement listed below, a brief explanation of your standard operating policies,
procedures, and standards to ensure that the following are done adequately to protect your customers' health.
MANAGEMENT AND CONTROL OF THE SYSTEM Do you budget money for the training of your employees
and managers? If yes, how much?
How will you ensure that employees in food preparation
and service are following your food safety rules?
What is your plan if power or water is interrupted; if there
is a terrorist threat; if there is a recall?
What is your plan if a customer complains that your food
made him/her sick?
What is your plan to ensure that thermometers are used
correctly and calibrated?
PREREQUISITE PROGRAMS Personal hygiene
How will you check to make sure that no sick employee is
working ?
What are your rules to ensure that employees wash hands
at correct times?
How do you ensure that hand washing facilities are
maintained and always stocked?
Environment and facilities
How do you ensure that there is adequate, safe hot and
cold water?
How do you provide for proper and timely disposal of
garbage, food waste, and recyclables?
What is your plan to ensure that the facility and
environment, to include the dumpster area, are kept
clean and maintained and pests are controlled?
Equipment
Who cleans equipment, when and how?
How do you verify that tableware and food preparation
equipment are adequately clean and sanitized?
How do you ensure that the wet wiping cloth sanitizer
solution is adequate?
What process do you use for hand dish washing?
What process do you use for mechanical dish washing
with a dish machine?
Supplies
How do you ensure that all supplies come from approved
suppliers?
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EVIDENCE OF AMC (cont'd)
Supplies (cont'd)
How do you ensure that supplies are stored correctly
[e.g., 6 inches (15 cm) above the floor] and chemicals
are separated from food?
How do you ensure that allergenic ingredients are
identified and separated? How do you ensure that
food in refrigerators is at less than 41ºF (5ºC), and
ready-to-eat food is covered, dated, and separate from
raw food, ready-to-eat food is on top, and inventory is
rotated using FIFO (first in first out)?
How do you ensure that dry goods are stored correctly?
How do you ensure that you do not over- or under-order
food?
FOOD HACCP PROCESSES What categories of Potentially Hazardous Foods / food
that require Temperature Control for Safety are
prepared and served (e.g., meat, fish / seafood, poultry,
raw eggs, etc.)?
How are the foods in each PHF / TCS category, above,
thawed?
Thawing process
Category
Meat Fish /
Seafood Poultry Other
Refrigeration
Running water less
than 70 F (21.1ºC)
Cooked frozen
Microwave
How do you ensure that raw fruits and vegetables eaten
uncooked are adequately disinfected?
If foods other than produce (i.e., meat, fish and seafood,
poultry, eggs) are washed or otherwise handled prior
to use, how will they be washed or handled?
How do you ensure that the cook adequately pasteurizes
the food?
How do you ensure that hot food is held, transported, and
served above 135ºF (57.2ºC)? What equipment is
used?
How do you ensure that cold food is held below 41ºF
(5ºC) during service? What equipment is used?
How do you ensure that hot food is cooled in 6 hours to
41ºF (5ºC) [i.e., food less than 2 inches (5 cm) deep in
pan; or less than 1 gallon (4 liters); ice bath; rapid
chill]?
How do you ensure that cold, ready-to-eat food is kept
cold, transported cold, catered cold, less than 41ºF
(5ºC), and used within 7 days?
How do you ensure that cold menu items are made with
cold ingredients and held at a temperature of less than
41ºF (5ºC)?
How do you ensure that ready-to-eat food between 135
and 41ºF (57.2 and 5ºC) is used within 4 hours, or food
between 41 and 70ºF (5 and 21.1ºC) is used in 6
hours?
What do you do with leftovers?
What do you do with take-out / donated food?